815 KAR 15:026. Existing boilers and pressure vessels; testing, repairs, inspection, and safety factors.

 

      RELATES TO: KRS 236.010, 236.030, 236.110, 236.240, 236.250, 236.990

      STATUTORY AUTHORITY: KRS 236.030

      NECESSITY, FUNCTION, AND CONFORMITY: KRS 236.030 requires the commissioner, through the Board of Boiler and Pressure Vessel Rules, to establish reasonable standards for the inspection and repair of boilers and pressure vessels. This administrative regulation establishes the requirements for safe maintenance of boilers and pressure vessels.

 

      Section 1. Frequency of Inspection of Existing Vessels. Upon notification by a boiler inspector, special inspector, or owner-user inspector, a boiler or pressure vessel subject to an annual or semiannual inspection pursuant to KRS 236.110 shall be prepared for the inspection or hydrostatic or other leak test by the owner or user.

 

      Section 2. Preparation for Inspections and Tests. (1) The owner or user shall prepare the boiler or pressure vessel for internal inspection and apply the required hydrostatic or other leak test on the date specified by the boiler inspector, special inspector, or owner-user inspector. The date set for inspection shall be a minimum of seven (7) days following notification by the boiler inspector, special inspector, or owner-user inspector.

      (2) The owner or user shall prepare a boiler for internal inspection pursuant to paragraphs (a) through (f) of this subsection.

      (a) Water shall be drawn off and the boiler thoroughly washed.

      (b) The manhole and handhole plates, washout plugs, and the plugs in water column connections shall be removed and the furnace and combustion chambers thoroughly cooled and cleaned.

      (c) The grate of an internally fired boiler shall be removed.

      (d) During the annual inspection, brickwork shall be removed as required by the boiler inspector or special inspector in order to determine the condition of the boiler, header, furnace, supports, or other parts.

      (e) The steam gauge shall be removed for testing.

      (f) Leakage of steam or hot water into the boiler shall be cut off by disconnecting the pipe or valve at the most convenient point.

      (3) If the boiler is jacketed and the longitudinal seams of shells, drums, or domes are not visible, enough of the jacketing, setting wall, or other forms, casing or housing shall be removed so that the size of the rivets, pitch of the rivets, and other data necessary to determine the safety of the boiler can be obtained.

      (4) If a boiler has not been prepared for an internal inspection in accordance with the requirements of this section or the owner or user fails to comply with the requirements for the hydrostatic or other leak test established in this administrative regulation, the boiler inspector or special inspector may decline to make the inspection or test and the inspection certificate shall be withheld until the owner or user complies with the requirements.

      (5) Lap seam crack. (a) A crack in the lap seam extending parallel to the longitudinal joint between or adjacent to rivet holes of the shell or drum of a boiler or pressure vessel shall cause the vessel to be immediately discontinued from use.

      (b) If the boiler or pressure vessel is not more than fifteen (15) years of age, a complete new course of the original thickness may be installed at the discretion of the boiler inspector, special inspector, or owner-user inspector and shall be after approval by the chief boiler inspector.

      (c) Patching shall be prohibited.

      (6) Hydrostatic pressure tests. If a hydrostatic test shall be applied to an existing installation, the pressure shall be as established in paragraphs (a) through (d) of this subsection.

      (a) For determining tightness, the pressure shall be equal to the release pressure of the safety valve or valves having the lowest release setting.

      (b) For determining safety or the strength of a vessel and associated piping as well as tightness, the test shall conform to the procedures and the pressure shall conform to the test pressures established in the original code of construction but not exceed one and one-half (1 1/2) times the maximum allowable working pressure (MAWP), except for a locomotive type boiler in which case the pressure shall be one and one-fourth (1 1/4) times the maximum allowable working pressure (MAWP). The pressure shall be under proper control to prevent the required test pressure from exceeding testing requirements listed in the original code of construction.

      (c) The temperature of the water used for the hydrostatic test shall not be less than ambient temperature, and shall not be less than seventy (70) degrees Fahrenheit for boilers or thirty (30) degrees Fahrenheit above the minimum design metal temperature for pressure vessels, nor high enough to allow the metal temperature to exceed 120 degrees Fahrenheit.

      (d) Minimum test pressure shall not be less than eighty (80) percent of the maximum allowable working pressure (MAWP) or the set pressure of the pressure-relieving device, whichever is greater.

 

      Section 3. Safety Factors in Existing Boilers and Pressure Vessels. (1) Maximum pressure and temperature. The maximum allowable working pressure (MAWP) and temperature for standard pressure vessels and boilers shall be determined in accordance with the ASME Code Edition (year and addenda) under which the boiler or pressure vessel was constructed and stamped.

      (2) Notice of accident or malfunction.

      (a) If an accident or malfunction renders a boiler or pressure vessel inoperative, the owner, user, or insurer shall immediately notify the Boiler Inspection Section and submit a detailed report of the accident or malfunction.

      (b) If there is a serious accident, including an explosion, resulting in property damage, injury to personnel, or loss of life, notice shall be given immediately by phone or electronic mail and the boiler, pressure vessel, or any of the parts shall not be removed or disturbed before an inspection has been made by a boiler inspector or special inspector, except for the purpose of saving a human life.

      (3) Condemned boilers. A boiler or pressure vessel inspected and found unsafe for further use by the chief boiler inspector or boiler inspector shall be stamped by the chief boiler inspector or boiler inspector with the letters "XX" prior to the letters "KY" and after the numbers to designate a condemned boiler or pressure vessel, i.e., XX Kentucky 12345 XX.

      (4) A person, firm, partnership, or corporation using or offering for sale a condemned boiler or pressure vessel for operation within this Commonwealth shall be subject to the penalties in KRS 236.990.

      (5) Nonstandard boilers and pressure vessels. Shipment of a nonstandard boiler, pressure vessel, or hot water supply boiler into this state shall be prohibited, unless exempted under KRS 236.060.

      (6) Used boilers. If a nonstandard boiler, pressure vessel, or hot water supply boiler is removed from use, the boiler, pressure vessel, or hot water supply boiler shall not be reinstalled.

      (7) Removal of safety appliances.

      (a) A person shall not attempt to remove or work on a safety appliance while a boiler or pressure vessel is in operation unless under the direction of a boiler inspector or special inspector or permitted under 815 KAR 15:040, Section 1(3)(j).

      (b) If a safety appliance is repaired during an outage of a boiler or pressure vessel, the appliance shall be reinstalled and in proper working order before the vessel is returned to service.

      (8) The boiler, pressure vessel, and pressure piping shall be maintained in accordance with the minimum requirements of the edition of the ASME Code that was in effect when the boiler, pressure vessel, and pressure piping was constructed and installed.

 

      Section 4. Used Vessels. (1) Used boilers or pressure vessels. Before a boiler or pressure vessel is brought into Kentucky for use, it shall be inspected by a boiler inspector or a special boiler inspector and the data shall be filed by the owner or user of the boiler or pressure vessel with the Boiler Inspection Section for approval.

      (2) Reinstalled boilers or pressure vessels.

      (a) If a boiler or pressure vessel is moved and reinstalled, the fittings and appliances shall comply with the ASME Boiler and Pressure Vessel Code, 2013 Edition, as established by KRS 236.040(2), and 815 KAR Chapter 15.

      (b) All pressure vessels for human occupancy shall comply with the ASME Safety Standard for Pressure Vessels for Human Occupancy, 2012 Edition, as established by KRS 236.040(3), and 815 KAR Chapter 15.

      (3) Unsafe conditions.

      (a) If the owner or user does not concur with the boiler inspector’s or special inspector's decision regarding the condition of the boiler or pressure vessel, the owner or user may appeal to the commissioner who may request a joint inspection by the chief boiler inspector and the boiler inspector or special boiler inspector.

      (b) Each boiler inspector or special inspector shall render a report to the commissioner, who shall render the final decision, based upon the data contained in all the inspectors’ reports.

 

      Section 5. Repairs and Alterations. (1) Repairs.

      (a) A repair shall require prior approval of a boiler inspector or special inspector and permits as required by KRS 236.240 and 236.250.

      (b) Repair to a boiler, pressure vessel, and the appurtenances thereto shall conform to the requirements of the National Board Inspection Code Part 3, 2013 Edition. Compliance with a later edition of the National Board Inspection Code shall be deemed equivalent and may be used in lieu of the edition specified.

      (c) Repairs to pressure relieving devices shall be made by a firm possessing the National Board Certificate of Authorization for Use of the Valve Repair (V-R) Stamp and the valve shall be stamped with the V-R stamp upon completion of the repair.

      (d) Repair to a boiler or a pressure vessel shall not be initiated without the authorization of the inspector, who shall be satisfied that the welding procedures and welders are qualified and that the repair methods are in accordance with the standards established in this administrative regulation.

      (e) The inspector may give prior approval for repairs of a routine nature. In every case, the inspector shall be advised of each repair under a prior agreement.

      (2) Alterations.

      (a) Except as permitted for owner-users, alterations to boilers and pressure vessels shall be performed by an authorized repairer.

      (b) Alteration to a boiler or pressure vessel shall not be initiated without the authorization of an inspector, who shall be satisfied that the alteration methods and calculations are in accordance with the standards established in this administrative regulation.

      (c) If the inspector considers it necessary, the inspector shall make an inspection of the object before granting authorization.

      (3)(a) It shall be the responsibility of the organization making the repair or alteration to coordinate the acceptance inspection of the repair or alteration.

      (b) Authorized repairers shall submit the appropriate National Board Inspection Code form to the division upon completion of repairs or alterations.

      (4) An owner-user inspector may perform acceptance inspections of repairs and alterations to boilers and pressure vessels if performed by the inspector’s employer.

 

      Section 6. Inspection by Special Inspectors. (1) A special inspector shall submit an inspection report to the Boiler Inspection Section in the Division of Plumbing on the applicable National Board Inspection Code Report of Inspection standard form or its equivalent.

      (2) An insurance company shall notify the Boiler Inspection Section of new or cancelled risks within thirty (30) days of each boiler or pressure vessel risk written, cancelled, or not renewed.

      (3) If a special boiler inspector finds, upon the first inspection of a boiler or pressure vessel, the boiler or pressure vessel or an appurtenance, a condition causing the special boiler inspector’s company to refuse or suspend insurance, the company shall immediately notify the Boiler Inspection Section and submit a report of the defect.

      (4) If an external inspection reveals evidence of a leak or crack, enough of the covering of the boiler or pressure vessel shall be removed to satisfy the boiler inspector or special inspector of its safety. If the covering cannot be removed at that time, the boiler inspector or special inspector shall order the operation stopped until the covering may be removed and a proper examination made.

 

      Section 7. Inspection by Owner-User Inspectors. (1) An owner-user inspector shall submit an inspection report to the Boiler Inspection Section in the Division of Plumbing on the applicable National Board Inspection Code Report of Inspection standard form, or its equivalent.

      (2) An owner-user company shall immediately notify the Boiler Inspection Section of a defective pressure vessel and submit a report of the defect.

      (3) If an external inspection reveals evidence of a leak or crack, enough of the covering of the pressure vessel shall be removed to satisfy the owner-user inspector of the pressure vessel’s safety. If the covering cannot be removed at that time, the owner-user inspector shall order the operation stopped until the covering may be removed and a proper examination made.

      (4) If there is a disagreement as to the acceptance of any condition of a pressure vessel or repair by the owner-user inspector and owner-user company, the department shall make the final determination in accordance with the standards established in this administrative regulation.

 

      Section 8. Inspection by Owner’s Piping Inspector (1) Owner’s piping inspectors shall inspect all new, replacement, and repaired piping for compliance to the applicable ASME piping code to which the piping is installed. The owner’s piping inspector shall sign the permit filed by the licensed contractor performing the piping installation or repair and forward it to the Boiler Inspection Section to show acceptance.

      (2) The owner’s piping inspector shall maintain copies of the material mill test reports and pressure test information including type of test, pressure at start and end of test, and duration of test. If welded joints are utilized, the file shall contain the qualified welder identification, weld procedure, and procedure qualification used.

      (3) If there is a disagreement as to the acceptance of any condition of the piping installation or repair by the owner’s piping inspector and owner’s user facility, the department shall make the final determination in accordance with the standards established in this administrative regulation.

 

      Section 9. Incorporation by Reference. (1) The "National Board Inspection Code Part 3", 2013 Edition, is incorporated by reference.

      (2) This material may be inspected, copied, or obtained, subject to applicable copyright law, at the Department of Housing, Buildings and Construction, Division of Plumbing, Boiler Section,101 Sea Hero Road, Suite 100, Frankfort, Kentucky 40601-5412, Monday through Friday, 8 a.m. to 4:30 p.m.

      (3) The National Board Inspection Code is also available, subject to applicable copyright law, from the National Board of Boiler and Pressure Vessel Inspectors, 1055 Crupper Avenue, Columbus, Ohio 43229. (20 Ky.R. 2756; Am. 2978; eff. 5-18-94; 23 Ky.R. 3621; 24 Ky.R. 94; eff. 6-25-1997; TAm eff. 8-9-2007; 42 Ky.R. 1625; 2113; eff. 2-5-2016.)